AGARD-AG-300 Vol. 13 AGARD-AG-300 Vol. 13 AGARD ADVISORY GROUP FOR AEROSPACE RESEARCH & DEVELOPMENT 7 RUE ANCELLE, 92200 NEUILLY-SUR-SEINE, FRANCE DTIC RELECTE RS Seca if AGARDograph 300 AGARD Flight Test Techniques Series Volume 13 on Reliability and Maintainabi (Fiabilité et maintenabilité) =] This AGARDograph, originally sponsored by the Flight Mechanics Panel on AGARD, +has been published on behalf of the Flight Vehicle Integration Panel Published February 1985 Distribution and Availabilty on Back Cover45 Sueré-Coour Bhd. 48, hou. Sve-Caer 5 ficou Holl, Quebec Hull Quebec) Communication Communication vu Qu Hull Qu Group Canada Printing Services Services Simprimerie May 5, 1995 To all recipients of AGARDograph AG-300, Vol 13, Reliability and Maintainability ‘We regret that this publication was printed with green covers, not blue ones. A replacement cover is enclosed for each copy we have sent you. Please attach one to those that you still have, and pass the remainder on to everyone to whom you have sent copies, with a request to them to do the same. ‘We apologize for this inconvenience. Yours sincerely, Kelly Edwards A/Project Manager AGARD Publications We Soar Sear Lo CanadaAGARD-AG-300 Vol. 13 Je GuaNI SS ADVISORY GROUP FOR AEROSPACE RESEARCH & DEVELOPMENT 7 RUE ANCELLE, 92200 NEUILLY-SUR-SEINE, FRANCE AGARDograph 300 Flight Test Techniques Series — Volume 13 Reliability and Maintainability (Fiabilité et maintenabilité) by JM, Howell 412 Test Wing/DOER 195 E. Popson Avenue Edwards Air Force Base, CA 93524-6841 United States ‘This AGARDograph, originally sponsored by the Flight Mechanics Panel on AGARD, hhas been published on behalf of the Flight Vehicle Integration Punel ' TAD _ North atiantc Treaty Organization TR —_Organisation eu tats ce ratantque Nord 19950630 134 “=The Mission of AGARD ‘According to its Charter, the mission of AGARD is to bring together the leading personalities ofthe NATO nations in the fields of science and technology relating to aerospace forthe following purposes — Recommending effective ways for the member nations to use thei research and development capabilites forthe ‘common benefit of the NATO community; — Providing seienitic and technical advice and assistance to the Military Commitee in the field of aerospace research and development (with particular regard to its military application); — Continuously stimulating advances in the aerospace sciences relevant to strengthening the common defence pasture; — Improving the co-operation among member nations in aerospace research and development; = Exchange of scientific and technical information; — Providing assistance to member nations for the purpose of increasing thee si — Rendering scientific and technical assistance, as requested, 10 other NATO bodies and to member nations in ‘connection with research and development problems inthe aerospace fed ‘The highest authority within AGARD is the National Delegates Board consisting of offically appointed senior representatives from each member nation. The mission of AGARD is earied out through the Panels which are composed of experts appointed by the National Delegates, the Consultant and Exchange Programme and the Aerospace Applications ‘Studies Programme. The results of AGARD work are reported tothe member nations and the NATO Authorities through the AGARD setes of publications of which this is one. Participation in AGARD activites is by invitation only and is normally Fimited to citizens of the NATTO nations ‘The content ofthis publication has been reproduced iretly from material supplied by AGARD or the authors, Published February 1995 Copyright © AGARD 1995 Al Rights Reserved ISBN 92-836-1014-8 Printed by Canada Communication Group 45 SacréCoeur Biv, Hull (Québec). Canada KIA 057Preface [At the request of the Advisory Group for Aerospace Research and Development (AGARD) Flight Mechanics Panel, the author atlempted to prepare a document outlining the rudiments of reliability and maintainability (R&M) evaluations conducted during initial Might test programs. Many military organizations prefer fo defer R&M evaluations until the new ‘equipment has been delivered tothe eventual user. Other organizations do not structure R&M engineering as an integral part Of the Might test team, The U.S. Air Force Flight Test Center at Edwards AFB, California has long conducted R&M evaluations during inital flight est and this document is written from that perspective ‘The AGARDograph presumes an entry level R&M engineering skill and does not dwell on R&M fundamentals. It is hoped that this AGARDograph will satisfy any need for understan Aight tes. ing of R&M evaluations conducted during inital Préface ‘Ata demande du Panel AGARD de la Mécanique du vol, auteur arédigé un document qui peSeate les principes de base des Evaluations de fablité et de maintenabilé (RAM) effeciuses lors des programmes des premiers esais en vol. Bon nombre © organisations militares choisissent de difrer les valuations RAM jusqu'a ce que Te matSrel neuf até récepionné par atlisateur. D'autes organisations préferent ne pas intégrer Mingsnicre R&M dans les fonctions de I'équpe d'essis en vol Depuis tds longtemps, fe centre dessus en vol de 'US Air Force & Edwards, en Calorie, réalise des valuations REM lors des premiers essais en vol et ee document est rédigé dans cette optique. La cure de cote AGARDographie ge, tous, un certain niveau de connaissances en Ingénierie RAM, Ce document doit permette une meilloure comprehension des Gvaluations RAM effectutes lors des premiers essais en vol. L (Paris omar pric 748 ‘Unsnneunced Just if ieats by. Digerabots eof 2 [avoniepiaiey Codes [piven aneAcknowledgement to Flight Test Editorial Committee Members Appleford, LK. Bever,G. Bothe, H. Campos, L.MB. Hildebrand, RR Kain, R van der Velde, RL. Van Norman, C. Zundel, Y. ASAEBUK Nasavvs, DLRIGE IsTIPO AFFICIUS NLRINE NLRINE ABFICIUS CEVIR RA, RUSSELL ‘Member, Flight Vehicle Integration Panel Chairman, Flight Test Editorial CommiteeTable of Contents Preface Acknowledgement Summary 1.0 Introduction 1.1 Purpose of Volume 1.2 Scope 1.3 Organization 1.4 Acknowledgments 2.0 R&M Test Objectives 2.1 Introduction 22 Reliability Maturation 23. Maintainability Maturation 24 Duty Cycle Improvement 25 Contractor Performance Verification 26 Deficiency Identification 2.7. Improvements 2.8 Mature System Capability 29° Logisties Requirements 2.10 Summary 30 Development/Aequisition Process 3.1 Requirements Definition 3.2 Contracwual Requirements 33 Design Reviews 3.4 Flight Readiness Reviews 4.0 Test Planning eral 4.2. Personnel 43. Test Asset Requirement 44 R&M Data Requirements 45. Flight Crew Debriefing 4.6 Maintenance Data 4.7 Maintenance Data Processing 48 Failure Analysis 4.9. Instrumentation Data 4.10 Instrumentation Data Processing 4.11 Safety 4.12 Joint Reliability and Maintainability Evaluation Teams ORMET) 5.0 Test Conduct 5.1 Initial Inspection 5.2. Schedule Maintenance/Servicing. 5.3. Unscheduled Maintenance/Reliability 54 Unscheduled Maintenance/Maintainabilty 55. Contractual Requirements Verification5.6 Builtin-Test 57 Summary 600 Data Analysis and Presentation 6.1 Production Readiness 6.2. Specification Verification 7.0 Reporting 7.1 General 72. Deficiencies 73. Progress Reports 74 Final Technical Reports 7S. Lessons Learned 7.6 Technical Society Papers 8.0 Follow-up 8.1 Accident Reports 82. In-Service R&M Data 8.3 Modification Requirements 9.0 Future Considerations 9.1 Processes 9.2 Technologies References Appendix A — Reliability and Maintainability Data Collection Elements Appendix B — JRMET Charter Annex AGARD Flight Test Instrumentation and Flight Test Techniques Series a 2 55RELIABILITY AND MAINTAINABILITY FLIGHT TEST TECHNIQUES by Jan M. Howell 412 Test Wing/DOER Edwards Air Force Base, California, USA Reliability and maintainability (R&M) evaluations can bbe conducted during the initial light test of new and ‘modified aerospace systems. Newly developed ‘equipment usually has only a fraction ofthe reliability needed. These evaluations, combined with extensive laboratory test efforts are required to bring the system to.an acceptable level of R&M performance. No flight time is normally dedicated to these R&M evaluations, ‘but some ground time is required. Other unique required resources include trained R&M engineering personnel, R&M data, and data reduction capability Results include identification of R&M deficiencies and ‘measurement of R&M parameters, 1.0 INTRODUCTION 1.1 Purpose of Volume ‘This AGARDograph provides information to the maintainability (R&M) of aeronautical weapons systems during initial flight test. Flight test R&M ‘evaluations are essential because R&M characteristics ‘cannot be predicted with any degree of success. Initial reliability for newly designed equipment is normally 10 to 20 percent of the predicted value, The actual reliability begins to approach the original prediction only after considerable laboratory and flight test. Table 1 lists the predicted reliability, laboratory test reliability, and the fleet use reliability for several difforent types of U.S. aeronautical equipment. The large differences between predictions, laboratory test, and actual use vividly show the need for indepth flight test R&M evaluations, This volume concentratcs on flight test because ofthe demonstrated need to evaluate systems during actual usage. Laboratory testing is discussed only as it relates to flight test. reader who must evaluate reliability and ‘Table 1 Specified, Predicted, Demonstrated, and Actual Reliability Meantime Between Failures in Hours (Data froma 1987 Rome Air Development Center, US. Air Force Study) i contract | CONTRACTOR | LABORATORY EQUIPMENT SPECIFIED _| PREDICTED. TEST ACTUAL USE ALQU3I u 59 a7 268 (F-4G radar warning |ALQ.35 13 169 231 66 |-15C radar waming) |APG-66 80 150 55 7 (F-16 attack radar) APQUIE 37 185 a2 2 (FB-111 attack radar) |ARC-164 1,000 1626 314 168 (-111 UHF radio) |ARC-164 1,000 1626 374 83 B-52H1 ULF radio)